Welding Answers

All rights reserved

This ebook or any part thereof must not be reproduced in any form without the written
permission of the publisher.

The information presented in this publication is for general information only. While it is
believed to be accurate, this information should not be used for any specific application
without competent professional examination and verification of its accuracy, suitability and
applicability by a licensed professional engineer, designer or architect.

Printed in the United States of America

First Printing: December 2015

Page | 1 Guide to Writing a Welding Procedure Specification | www.WeldingAnswers.com

 CONTENTS

Preface 3

Section 1 – WPS or PQR 5

Section 2 – Documentation 6

Section 3 – Joint Design 7

Section 4 – Position 9

Section 5 – Base Metals 10

Section 6 – Electrical Characteristics 11

Section 7 – Filler Metals 12

Section 8 – Shielding 12

Section 9 – Technique 14

Section 10 – Preheat 15

Section 11 – Postweld Heat Treatment 16

Section 12 – Welding Procedure 17

Appendices 19

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 PREFACE

Welding Engineers and CWIs are not the only ones tasked with writing a Welding
Procedure Specification (WPS). It is true that these professionals are more often
than not responsible for creating these documents, but in many cases other
individuals may have to carry out this important task. Anyone from a production
manager to a welder can be faced with writing a WPS. Although it seems
daunting even to qualified professionals it does not have to be.

Typically when we talk about developing a WPS we are simply talking about taking
an existing welding procedure and documenting it. The purpose of the WPS is to
ensure that we are getting sound welds consistently. The WPS will put upper and
lower limits to the essential variables such as amperage, voltage, electrical
stickout, etc. In some cases “writing” a WPS involves developing a procedure.
Your company receives a new job and has to figure out how to weld it. If you get
tasked with creating the WPS you not only have to document a procedure, but
rather make many decisions in selecting welding process, filler metal, any kind of
heat treatment, essential variables, etc.

In this guide we’ll walk you through the all sections of a WPS and explain every
single piece of information you should include. A WPS will contain essential and
non-essential variables. Albert J. Moore, Jr. of the AWS Certification Committee
says the following regarding this distinction in essential and non-essential
variables in a WPS: “Welding variables that are critical to making acceptable welds
are categorized as essential variables. Welding variables that do not have a
profound influence on the mechanical properties of the weld or those that are
associated with the skills of the welder are categorized as non-essential.” In
essence, essential variables are those that can affect the mechanical properties

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of weld such as tensile strength and ductility. Non-essential variables do not have
a significant effect.

There is a lot of disagreement between professionals as to which are essential

and non-essential variables. Our recommendation is that you take the WPS form
given by the code and standard you are following and fill it out completely.

Over the next few pages we will walk you step by step in filling out the AWS
D1.1/D1.1M Welding Procedure Specification form found on the D1.1 Code Book.
Our expectation is that you can fill out your WPS completely after reading through
this guide. As always, you can send us your questions through our website at
www.WeldingAnswers.com

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 SECTION 1
WPS or PQR

Figure 1 – Section 1 of WPS

1. In this top section of the form you are specifying whether this document is
for documenting a Welding Procedure Specification (Check the first YES
box) or a Procedure Qualification Record (Check bottom YES Box). If this
WPS is prequalified place an “X” next to PREQUALIFIED. If qualified by
testing then place the “X” next to QUALIFIED BY TESTING.

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 SECTION 2 - DOCUMENTATION
This section of the WPS will provide documentation and traceability. It is
especially important that the appropriate Procedure Qualification Record (if any)
is referenced.

Figure 2 – Section 2 of WPS

2. Enter the name of the company that owns the WPS – this is typically the
company that will be doing the welding.

3. Enter the type of welding process to be used (i.e. SAW, GTAW, SMAW,
FCAW-S, FCAW-G, GMAW, etc.)

4. Reference the Procedure Qualification Record that was used to verify this
procedure. If this is a prequalified WPS simply write “Prequalified” on the
line.

5. This is the identification number for the Welding Procedure Specification

you are developing. You can choose your numbering/documenting system.
Fore example, you can call this “WPS 001.”

6. Enter the revision number. If it’s the original enter “1”.

7. The date of WPS was written or revised.

8. Person or entity in charge of the developing of the WPS.

9. Person or entity that authorized the WPS.

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 10.Date in which it was authorized.

11.In this area you specify the level of automation. Examples of manual would
be SMAW and GTAW performed by a person. Semi-Automatic would be
any wire process such as GMAW or FCAW performed by a person. Machine
typically means a hard-automation system such as a SAW system that still
requires significant operator involvement. Automatic is typically soft
automation such as a welding robot.

SECTION 3 – JOINT DESIGN

In this area of the WPS we provide details about the type of joint and its
geometry. More detail can be provided on the sketch of the joint on the Welding
Procedure section; however, be as detailed as possible in this section.

Figure 3 – Section 3 of WPS

12.The type of weld will be “Butt” or “Fillet”. Lap welds typically will be
labeled “Fillet” as well. Then specify whether it is a single or double sided
weld.

13.If a backing material will be used, such as the one used on an AWS test
plate, put an “X” on YES.

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 14.Specify the type of backing material, preferably using an ASTM or SAE
number to identify the material.

15.This is the opening or gap between the two pieced being welded. Also
called root gap as seen below.

Figure 4 – Groove Weld Joint Terminology

16.This is typically “0” when using a backing material. In some joints such as a
pipe joint where there is no material the edges on the bottom of the
beveled joint will be flattened to create a “land”. If this was not done it
would be very hard to not blow through the joint if the root gap is too big.
In this space enter the dimension of the face of the root.

17.Also called the “included angle.” This is the sum of the angle of both
beveled edges on a butt weld. If each plate is beveled at 17.5 degrees then
the groove angle would be 35 degrees. See Figure 4 above for distinction
between bevel angle and included angle.

18.If the edge is not straight as the in Figure 4 but rather a J- or U-groove enter
the radius at the bottom of the joint. ¼” in the Figure 5 below.

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 Figure 5 – U-Groove with ¼” radius

19.If back gouging is necessary place an “X” on the YES box.

20.If back gouging then specify what method will be used (i.e. carbon arc
gouging, plasma gouging, etc.)

SECTION 4 – POSITION
In this section we provide information related to the position of the joint (flat,
horizontal, overhead or vertical) and also direction of travel when the weld is
vertical.

Figure 6 – Section 4 of WPS

21.If the WPS is for a groove weld enter the the groove positions (i.e. 1G, 2G,
3G, 5G, 6G)

22.If the WPS is for a fillet weld enter the fillet position (i.e. 1F, 2F, 3F, 5F)

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 23.If the position is vertical (3G or 3F) state whether the weldnig is done
vertical up (from bottom to top) or veritical down (from top to bottom).
Place an “X” on the appropriate box.

SECTION 5 – BASE METALS

Here we provide information on the base metal or metals being used.

Figure 7 – Section 5 of WPS

24.The material specification is the number assigned to the type of material

being welded by the American Society for Testing and Materials (ASTM).
This specification can be of another numbering system as long as it is
consistent with the rest of the WPS.

25.ASTM specifications will sometimes have more than one grade. In this
space enter the grade. For example, ASTM 572 has five different grades
(Grades 42, 50, 55, 60, 65).

26.State the thickness of the plates being welded for groove welds.

27.State the thickness of the plates beting welded for fillet welds.

28. If welding on pipe, which would be a groove weld, specify the pipe
diameter.

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 SECTION 6 – ELECTRICAL CHARACTHERISTICS
The type of current being used is noted in this section. Also, if using the GMAW
(Mig) process we also specify the type of metal transfer used.

Figure 8 – Section 6 of WPS

29.If using the GMAW Process specify the mode of metal transfer.

30.Specify the type of current being used. AC is alternating current, DCEP is

direct current electrode positive (also called DC+ or reverse current), DCEN
is direct current electrode negative (also called DC- or straight current). If
other then state the type of current (this is not typical).

31.If using the GTAW (Tig) process then specify the size (diameter) of tungsten
being used.

32. If using GTAW (Tig) process specify the type of tungten being used (i.e.
pure, 2% thoriated, etc.)

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 SECTION 7 – FILLER METALS
A Welding Procedure Specification should always be very specific as to what filler
metal or filler metals can be used. AWS specification and classifications for filler
metals are very specific. In this section you just reference these. The specification
relates to the welding process (GMAW, FCAW, SMAW, etc.) and the base material
(carbon steel, stainless steel, aluminum, and others).

Figure 9 – Section 7 of WPS

33.State the AWS Specification. For example, if using the GMAW process this
would be AWS A5.18. For a list of AWS Specification see Appendix RR

34.The AWS Classification referes to the specific type of filler being used (i.e.
ER70S-6, E70T-1, etc.).

SECTION 8 – SHIELDING
The only arc welding process that do not use external shielding are SMAW (Stick)
and FCAW-S (Self-shielded Flux-Cored). All other will have a shielding gas or flux.
Specify the gas or flux in this section.

Figure 10 – Section 8 of WPS

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 35.If using the Submerged Arc Welding process (SAW) specify the flux being
used. Fluxes on their own do not have an AWS classification. Here simply
enter the trade name for the the flux (i.e. Lincolnweld 860).

36.If using the SAW process enter the Electrode-Flux classification. This
number cosists of the electrode classification used on field 34 and the flux.
Please note that the “-Flux” part varies even if the same flux is used with
different wires. This second part of the provides information on the
mechanical properties of the deposited weld metal (i.e. EM12K –F7A4).

37.If using a process that requires shielding gas such as GMAW, GTAW, FCAW-
G specify the gas. For example, Argon Mix.

38.Here you provide specifics about the gas. If you are using an Argon mix
here you would enter the percentage of Argon in the gas and the
percetage(s) of the other gas(es). For example, 90%Argon, 10%Carbon
Dioxide.

39.Speficy the desired flow rate in cubic feet per hour (CFH). This can be range
(i.e 45-50 cfh).

40.If using the GTAW process specify the gas cup size. This is the diameter of
the cup where the tungsten comes out.

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 SECTION 9 – TECHNIQUE
Technique is an important variable in welding. It may not make much of a
difference on single pass welds (whether we weave or not), but on large,
multiple pass welds it will affect the size of the weld nugger which in turn
affects the mechanical properties. It is important to specify what technique is
to be used. Other information for automatic welding is also specified in this
section as well as any cleaning or peening between passes.

Figure 11 – Section 9 of WPS

41.Specify whether the WPS calls for a stringers (moving electrode in a straight
line) or weave bead. There are several types of weave – you can choose to
specify the type here as well. For example, box weave, straight weave, etc.

42.Specify if this is a single-pass or multiple-pass weld. If you have a fillet weld

and you are putting one pass on each side of the T-joint it would be a single
pass weld.

43.Enter the number of electrodes being used. Most of the time you will only
be running one electrode. Some processes such as tandem mig (two wires)
and tandem subarc (2+ wires) are used.

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 44.If using a multi-wire process you need to provide information regarding the
spacing of the electrodes. Longitudinal spacing refers to the distance of the
electrodes from front to back.

45.If using a multi-wire process specify the side-to-side distance between the
electrodes.

46.Specify the angle at which the electrodes are being fed. Not always will the
wire feed parallel so you will need to state the angle of each electrode.

47.This is the distance between the end of the contact tip (contact tube) and
the work piece. Keep in mind that this is sometimes called electrical
stickout (ESO). Electrical stickout and visible stickout can be different if the
tip is recessed into the nozzle or if it sticks out of the nozzle. In this space
we want electrical stickout. This is also called Contact Tip to Work Distance
(CTWD).

48.If peening is necessary after each pass specify it here.

49.If cleaning is necessary between passes specify it here. This can be “wire
brush”, “slag removed”, etc.

SECTION 10 – PREHEAT
Preheating the base material is not often necessary. Typically once you get into
thicker sections (around 1-inch and above) or are using high strength materials is
when preheat will be necessary. If you think your base material may require
preheat you can consult Table 3.2 of the AWS D1.1 code.

Figure 12 – Section 10 of WPS

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 50.If preheat is necessary state the minimum temperature to which the part
needs to be heated.

51.The welding process heats the part; however, at times it is necessary to

increase the temperature of the part between passes. This could be due to
cooling of the part during the time interpass cleaning is being done. Specify
the minimum interpass temperature here. Typically it will be the same as
the preheat temperature.

52.If there is a specific temperature that must not be exceeded before making
a pass (weld) state it here.

SECTION 11 – POSTWELD HEAT TREATMENT

If your procedure called for preheat it may very well also need some kind of
postweld heat treatment (PWHT). When we talk about PWHT we are refering to
holding the material at a certain temperature for a specific amount of time.
Slow-cooling a part after welding with a heating blanked or other method is not
PWHT. However, you can add notes in this section if you would like to slow-cool
the part.

Figure 13 – Section 11 of WPS

53. If postweld heat treatment is necessary specify the temperature at which the part must held.

54. If postweld heat treatment is necessary specify the amount of time that the part must kept at
the specified postweld heat treatment temperature.

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 SECTION 12 – WELDING PROCEDURE

This section of the WPS brings it all together. Take advantage of the “Joint
Details” section to include as much detail about the joint as you can via a sketch.
Appendix B provides a good example of how to use this area to your advantage.
Everything on this section has already been specified above; however, this is that
the welder will be looking at almost 100% of the time once he has his welder and
filler metals in place.

Figure 14 – Section 12 of WPS

55.In this section we will number all the welds of a multiple pass weld. If all
the passes for the desired weld have the exact same procedures then we
only need to list it once. In this field enter “ALL.” If the procedure vary
between passes then list all passes individually. Also, if you have one
procedure for the root pass, one for the fill passes, and one for the cap
passes you can list only three line (i.e. 1, 2-9, 10-11). Or you can also place
the names (Root, Fill, Cap).

56.Specify the process (GMAW, SAW, GTAW, etc.).

57.Specify the electrode classification (i.e. ER70S-9, E71T-1, EM12K, etc.)

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 58.Specify the diameter of the electrode.

59.Specify the polartiy (AC, DCEP, DCEN)

60.Specify the amperage or wire feed speed ranges that are acceptable for this
welding procedure. Typical ranges of amperage or wire feed speed are +/-
10% from the current used when testing the procedure. This can be notes
as 250A +/- 10% or 225-275A. Same with wire feed speed.

61.Specify the voltage range. Voltage ranges are typically a bit narrower, +/-
5-7%.

62.Specify the travel speed. This can also be arange (i.e. 16-18ipm).

63.In this area provide a graphical representation of the joint. You can include
information on the joint such as root opening, root face dimension, plate
thickness and groove angle. You should also show the placement and
sequence of passes which will also show the desired number of passes.

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 APPENDICES

Appendix A – WPS/PQR Form

Appendix B – Sample WPS Form

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 APPENDIX A - WPS/PQR FORM

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 APPENDIX B - EXAMPLE OF A WELDING PROCEDURE SPECIFICATION

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 Welding Answers
All rights reserved

This ebook or any part thereof must not be reproduced in any form without the written
permission of the publisher.

The information presented in this publication is for general information only. While it is
believed to be accurate, this information should not be used for any specific application
without competent professional examination and verification of its accuracy, suitability and
applicability by a licensed professional engineer, designer or architect.

Printed in the United States of America

First Printing: December 2015

Page | 22 Guide to Writing a Welding Procedure Specification | www.WeldingAnswers.com